Overview Of Scion Research : Bioplastics Alan Fernyhough, 20th October, 2011

Scion – who we are

NZ Forest Research Institute Ltd • One of 8 Crown Research Institutes • Established in 1947 • 44M NZD turnover • 340 science and support staff • Based primarily in Rotorua

− Christchurch, Wellington and Auckland

Scion – what we do • Forestry skills transitioned to bioeconomy skills • Core Purpose: innovation & growth in ...forestry, wood & biomaterials • Three Research Groups

− New Forests and Forest Science (biosecurity, breeding programs, fire)

− Sustainable Design (environment, climate change, optimising land value, bioenergy)

− Manufacturing & Bioproduct Development (~80) • Polymers & Chemicals • Wood & Fibres (inc. pulp/paper & packaging) • Biotransformations

(biomaterials/bioenergy, industrial biotech, wood and plant fibre, advanced packaging)

Bioplastics Roadmap (Updated 2011) & Bioplastics Research at Scion

Outcome 1: New manufacturing and packaging technologies implemented for bioplastics & related biomaterials

Outcome 2: Increased NZ biomaterial content in exported plastic products

Outcome 3: Reduced materials/ manufacturing costs associated with new biomaterials

Outcome 4: NZ made biopolymer/chemical manufacturing demonstrated in plastics

Outcome 5: Scion maintained as an internationally recognised leading Centre of Expertise in integrated bioplastics technologies

SCION BIOPLASTICS ROADMAP: PRIORITIES & OPPORTUNITIES

• Enhanced exports for sectors using plastics (packaging or parts) - drawing on distinctive performance & lower footprint manufacturing technologies

• Support New Zealand manufacturers & primary exporters/brand owners in bioplastics and related materials technologies/expertise

Scion Bioplastics Research Summary • Make: new bio-monomers, polymers & additives

− Extractions (NZ resources) − Chemical reactions & polymerisations − Microbial polymerisations & gene technologies − Biopolyesters & precursors ... − Functional chemical/polymer additives

• Modify: plastics for new performance

− Extrusion compounding & reactive extrusion / processing Long wood fibres Functionalised pulps & biomasses Extractives/additives/polymers/minerals (where feasible from NZ/above)

• Mould: demonstrator plastic products (testing/industry transfer)

− Injection Moulding / Extrusion − Thermoforming / Film − Foam − (Rotational Moulding)

Scion Bioplastics Research Summary

Example NZ biomasses & waste streams

• Wood & Forestry Processes

• Pine Bark

• Other NZ Natural Fibres/Biomasses

• Other NZ Natural Extractives

• NZ Processing Waste Streams

• NZ Minerals

Make – Modify - Mould

Scion – Bioplastics Research Three Example Commercial Developments using functionalised “biomasses” 1. BioPeg : Controllably Degradable Bioplastics 2. KiwiPlast : Bioplastics From Fruit Waste 3. LignoMaxx® : Lignotech STEX Functional Additives

1. Controllably Degradable Bioplastics

The Technology? Biomass modified bioplastics Compatibilised / stabilised forestry residues Plastics processability & stability Mechanical integrity Differential degradation rates

Demonstration Product/Process Specific 1st Application: Erosion Control Peg Two component design by Mulford Replaces steel or ABS Natural, renewable and degradable materials Tough enough to be hit with a hammer

1. Controllably Degradable Bioplastics: Commercialisation Status Compounded via Clariant under license Biopegs moulded by Mulford (Ludowici) Biopegs marketed by Maccaferri Plastics

What’s new ? / Future Wider synergistic applications

“Safely degradable” Tree protectors, plant pots,.... Water/marine applications Controlled release of actives

Horticulture Animal health / Vet.

safely degradable

1. Further New Products: Biomass Modified Bioplastics: Recyclable, Compostable Cosmetics Pot

• Biobased and natural

• NZ resources

• Heat resistant PLA

base

• Tolerant to hot-fill oils, waxes

2. KiwiPlast: Bioplastic Products from Fruit Wastes

The Technology? Processed fruit waste biomass-bioplastic Compatibilised / stabilised Effective full utilisation of whole fruit waste/residues Plastics processability / stability Mechanical integrity

Demonstration Product/Process Specific 1st Application: Zespri Spife Existing polystyrene spife

Natural, renewable: kiwifruit residue derived End-of-Life compostable

2. KiwiPlast - Commercialisation Status

Commercial processing-compounding (Scion & industry) Injection moulding trials (Scion & industry) Materials & processing logistics substantially addressed Initial test marketing / consumer study

What’s new? / Future

New designs / similar products Further testing Wider synergistic applications

Packaging Other applications & other biomass residues

2. New Bio-spifes: Manufacturing Trials

2. New Products & Further Manufacturing Trials: Packaging Film & Thermoformed Trays

3. LignoMaxx Bio-additive for Plastics & Bioplastics

Stages 2 & 3: Modifications & Extrusion

innovative, sustainable, plastically processable functional biomaterial –

injection moulded etc

The Technology: Steam Explosion (STEX) of Biomass

Enhances (for biomass): Flow Reactivity Compatibility Functionality Uniformity/reproducibility

Stage 1: Lignotech STEX Biomass Treatment

3. LignoMaxx: Pallet Trial (US): 40wt% STEX DDGS

Demonstration Product • Applied to DDGS (Dried Distillers Grains & Solubles) • By-product of US corn ethanol production • Non-food source feedstock/readily available • US Freight pallet

Status • US National Composites Centre • Passed tests/specifications (pallets) What’s new ? & Future • Improved mouldability • Further commercial trials • Other products / biomasses • Up-cycling plastics / recyclates

Examples of other Bioplastics Research

Microbial Bioplastics (PHAs) - from Biomass/Wastes

The Technology wastewater/wastes microbes PHA filled bacteria

O2 N2 PHA Polyester

Downstream extraction to polymer & processing / products

What’s new? / Future

Mixed culture

S-effluent

0 10 20 30 40 50 60 70 80 90

% PHA

Mixed culture

P- effluent

Mixed culture A- feed

Mixed culture C-feed

Y88T G - feed

• PHA Productivity • Various biomass/sugar feedstocks & wastes • Whole cell processing : avoids expensive extraction • Downstream integrated processing • Continuous scale-up production & harvesting • Modified/New PHA biopolymers - gene technologies

Waste To Gold Pilot Plant: Waste to Energy (Scion-RDC)

Future: Scale Up / Adapt for Waste to Plastics?

0

1

2

3

4

5 Impact Strength (KJm-2)

Long Fibres can improve Impact Strength of PLA

PLA PLA + 30% LFF

PLA + 30% LRF

PLA + M

PLA +30%MLFF

PLA +30%MLRF

Lignin Research

• Biofuels

• Pulp / Fibres

• Co-products o extractives o lignin

for every 1 litre biofuel from wood ~1 kg of lignin is co-produced replacing 10% of NZ’s oil imports with softwood liquid biofuel could generate ~1 Mt lignin

• Lignin in plastics & composites • Lignin in adhesives & coatings • Lignin in fibres • Lignin chemicals & intermediates

Monitoring/altering lignin in plants/trees

Lignin extraction/fractionation

Lignin analytical methods

Controlled chemical/enzymatic breakdown & reactions: monomers/resins/chemicals (VTT-LigniVal & others)

Polymers, Biomasses, Extractives & Additives: Screening & Databases

140 160 180 200 220 240 2601

10

100

1000

10000

100000

1000000

1E7 A040108 190C control no CESA A020108 190C 190C 2% CESA A010108 190C 220C noCESA A030108 190C 220C 2% CESA A060108 190C 200C noCESA A070108 190C 240C 2% CESA A050108 190C 200C 2% CESA PLA 3051D

G' [M

Pa]

Temperature [OC]

-40 -20 0 20 40 60 80 100 120 140

10000

100000

1000000

1E7

1E8 PS commercial tray (black) AT030208 Butane only AT020208 Butane 2% CESA AT010208 Butane 1% Methylal

E' [

Pa]

E'' [

Pa]

Temperature [OC]1000 10000 100000 1000000

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

190OC 190OC CE MB 240OC 240OC CE MB

dw/d

(logM

w)

Molecular weight

Rheology : processing stability/windows; melt strength enhancements; recycling; crosslinking,..

GPC polymer molecular weight: degradation; chain extension, branching, processing rheology correlations., ...

DMTA : thermal resistance under load/HDT; service temperatures, ....

TGA : thermal stability: processing windows/ stabilisation strategies ..

2. Heating cycle (free of thermal history)

-1.0

-0.8

-0.6

-0.4

-0.2

0.0

0.2

Hea

t Flo

w (W

/g)

-50 0 50 100 150 200

Temperature (°C)

35BM untreated moulded.001––––––– 44BM 10pct Gly moulded.001– – – – 44BM 25pct Gly moulded.001––––– · 44BM extruded.001––– – – 44BM powder untreated.001––– –––

Exo Up Universal V4.5A TA Instruments

Solid State 13 C NMR

Polymers, Biomasses, Extractives & Additives: Screening & Databases FTIR, NMR, GC-/,

LC-/,MS,UV, ICP ,..: chemical composition & changes,....

Microscopy: morphology compatibility, dispersion, ..

UV /accelerated weathering : degradation-durability; colour; aging effects/inhibition

Microbial/fungal challenge/decay tests degradation-durability,

DSC/MDSC – thermal transitions, reactions & crystallinity in polymers

Petroleum Fuels, Chemicals & Plastics

CRUDE OIL

PLASTIC PRODUCTS

CHEMICAL BUILDING BLOCKS/MONOMERS

POLYMERS PE,PP,PVC,PS,PET,..

ADDITIVES: chemicals/polymers;

fillers/fibres

PETROLEUM REFINING

POLYMERISATION

COMPOUNDING & PROCESSING

FUELS & OILS

extrusion, moulding foaming,..

PETCHEM FEEDSTOCKS (~3%)

Biomass BioFuels, BioChemicals & BioPlastics

BIOMASS

BIOPLASTIC PRODUCTS

CHEMICAL BUILDING BLOCKS/MONOMERS

BIOPOLYMERS

extrusion, moulding foaming,..

POLYMERISATION

COMPOUNDING & PROCESSING

SUGARS

LIGNIN,…

EXTRACTIVES

BIOMASS REFINING

ADDITIVES: (fibres/fillers; chemicals/polymers)

PULPS (FIBRES)

FUNCTIONALISED BIOMASSES

Thank You